Systems and methods for storing, retreiving and processing objects including stackable semicircular towers

ABSTRACT

A storage, retrieval and processing system is disclosed for processing objects. The system includes a plurality of bins including objects to be distributed by the processing system, said plurality of bins being provided in at least a partially generally circular arrangement, a programmable motion device that includes an end effector for grasping and moving any of the objects, said programmable motion device being capable of reaching any of the objects within the plurality of bins, and a plurality of destination containers for receiving any of the objects from the plurality of bins, said plurality of destination containers being provided in a region that is generally within the at least partially generally circular arrangement of the plurality of bins.

PRIOIRITY

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 62/471,656 filed Mar. 15, 2017, the disclosure ofwhich is hereby incorporated by reference in its entirety.

BACKGROUND

The invention generally relates to storage and retrieval systems, andrelates in particular to automated storage and retrieval systems thatare used with systems for processing objects.

Automated storage and retrieval systems (AS/RS) generally includecomputer controlled systems of automatically storing (placing) andretrieving items from defined storage locations. Traditional AS/RStypically employ totes (or bins), which are the smallest unit of loadfor the system. In these systems, the totes are brought to people whopick individual items out of the totes. When a person has picked therequired number of items out of the tote, the tote is then re-inductedback into the AS/RS.

In these traditional systems, the totes are brought to a person, and theperson may either remove an item from the tote or add an item to thetote. The tote is then returned to the storage location. Such systems,for example, may be used in libraries and warehouse storage facilities.The AS/RS involves no processing of the items in the tote, as a personprocesses the objects when the tote is brought to the person. Thisseparation of jobs allows any automated transport system to do what itis good at—moving totes—and the person to do what the person is betterat—picking items out of cluttered totes. It also means the person maystand in one place while the transport system brings the person totes,which increases the rate at which the person can pick goods.

There are limits however, on such conventional systems in terms of thetime and resources required to move totes toward and then away from eachperson, as well as how quickly a person can process totes in thisfashion in applications where each person may be required to process alarge number of totes. There remains a need therefore, for an AS/RS thatstores and retrieves objects more efficiently and cost effectively, yetalso assists in the processing of a wide variety of objects.

SUMMARY

In accordance with an embodiment, the invention provides a storage,retrieval and processing system for processing objects. The systemincludes a plurality of bins including objects to be distributed by theprocessing system, said plurality of bins being provided in at least apartially generally circular arrangement, a programmable motion devicethat includes an end effector for grasping and moving any of theobjects, said programmable motion device being capable of reaching anyof the objects within the plurality of bins, and a plurality ofdestination containers for receiving any of the objects from theplurality of bins, said plurality of destination containers beingprovided in a region that is generally within the at least partiallygenerally circular arrangement of the plurality of bins.

In accordance with another embodiment, the invention provides a storage,retrieval and processing system for processing objects that includes aplurality vertically stacked levels of a plurality of bins includingobjects to be distributed by the processing system, a programmablemotion device, and at least one destination container for receiving anyof the objects from the plurality of levels of the plurality of bins.The plurality of bins is provided in at least a partially generallycircular arrangement. The programmable motion device includes an endeffector for grasping and moving any of the objects, and is capable ofreaching any of the objects within the plurality of levels of theplurality of bins. The at least one destination container is provided ina region that is generally within the at least partially generallycircular arrangement of the plurality of bins and is movable with theprogrammable motion device.

In accordance with a further embodiment, the invention provides a methodof storing, retrieving and processing objects. The method includes thesteps of providing a plurality of bins including objects to beprocessed, said plurality of bins being provided in at least a partiallycircular arrangement, receiving at least one destination containerwithin an area at least partially enclosed by the at least partiallycircular arrangement of the plurality of bins, moving the end effectorof the programmable motion device toward the at least one bin of theplurality of bins, grasping an object from the at least one bin usingthe end effector, moving the object with the end effector toward the atleast one destination container, and placing the object in the at leastone destination container with the end effector.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description may be further understood with reference tothe accompanying drawings in which:

FIG. 1 shows an illustrative diagrammatic view of a storage, retrievaland processing system of an embodiment of the present invention thatincludes an array of bins in an at least partially circular arrangement;

FIG. 2 shows an illustrative diagrammatic view of a drawer containing abin for use in a system of FIG. 1;

FIG. 3 shows an illustrative diagrammatic view of a storage, retrievaland processing system of an embodiment of the present invention thatincludes an array of bins in an at least partially circular arrangementas well as a programmable motion device and a plurality of destinationlocations;

FIG. 4 shows an illustrative diagrammatic view of a perception systemfor use in a storage, retrieval and processing system of an embodimentof the present invention;

FIG. 5 shows an illustrative diagrammatic view from the perceptionsystem of FIG. 4, showing a view of objects within a bin of objects tobe processed;

FIGS. 6A and 6B show an illustrative diagrammatic view of a graspselection process in a storage, retrieval and processing system of thean embodiment of the present invention;

FIGS. 7A and 7B show an illustrative diagrammatic view of a graspplanning process in a storage, retrieval and processing system of the anembodiment of the present invention;

FIGS. 8A and 8B show an illustrative diagrammatic view of a graspexecution process in a storage, retrieval and processing system of thean embodiment of the present invention;

FIG. 9 shows an illustrative diagrammatic view of an automated carriertogether with a destination container being carried by the carrier in astorage, retrieval and processing system of the an embodiment of thepresent invention;

FIG. 10 shows an illustrative diagrammatic top view of the carrier anddestination container shown in FIG. 9;

FIG. 11 shows an illustrative diagrammatic view of a storage, retrievaland processing system of an embodiment of the present invention thatincludes a plurality of levels of arrays of bins in an at leastpartially circular arrangement;

FIG. 12 shows an illustrative diagrammatic view of a storage, retrievaland processing system of another embodiment of the present inventionthat includes a plurality of levels of arrays of bins in an at leastpartially circular arrangement, wherein at least some of the levels arefully circular;

FIG. 13 shows an illustrative diagrammatic plan view of a storage,retrieval and processing system of another embodiment of the presentinvention that includes a continuous track system by that may be used bycarriers for moving destination containers;

FIG. 14 shows an illustrative diagrammatic view of another automatedcarrier together with a destination container being carried by thecarrier in a storage, retrieval and processing system of the anembodiment of the present invention for use on the continuous tracksystem of FIG. 13;

FIG. 15 shows an illustrative diagrammatic top view of the carrier anddestination container of FIG. 14;

FIG. 16 shows an illustrative diagrammatic bottom view of the carrierfor use on the continuous track system of FIG. 14;

FIG. 17 shows an illustrative diagrammatic plan view of a storage,retrieval and processing system of a further embodiment of the presentinvention that includes a discontinuous track system by that may be usedby carriers for moving destination containers;

FIG. 18 shows an illustrative diagrammatic view of a further automatedcarrier together with a destination container being carried by thecarrier in a storage, retrieval and processing system of the anembodiment of the present invention for use on the discontinuous tracksystem of FIG. 17;

FIGS. 19A and 19B show illustrative diagrammatic isometric views of thecarrier of FIG. 18 with the wheel assemblies in each of two differentpivotal positions;

FIGS. 20A and 20B show illustrative diagrammatic side views of thecarrier shown in FIGS. 19A and 19B taken along lines 20A-20A and 20B-20Brespectively;

FIGS. 21A and 21B show illustrative diagrammatic end views of thecarrier shown in FIGS. 19A and 19B taken along lines 21A-21A and 21B-21Brespectively;

FIGS. 22A and 22B show illustrative diagrammatic bottom views of thecarrier shown in FIGS. 19A and 19B respectively;

FIGS. 23A and 23B show illustrative diagrammatic views of pivotal wheelassemblies for use in a carrier of an embodiment of the presentinvention in each of two positions;

FIGS. 24A and 24B show illustrative diagrammatic bottom views of thecarrier shown in FIGS. 19A and 19B respectively with track sectionssuperimposed thereon for illustrative purposes;

FIGS. 25A-25C show illustrative diagrammatic views of the carrier ofFIG. 18 at different stages of engaging an adjacent track section duringmovement;

FIG. 26 shows an illustrative diagrammatic view of guide rollers of thecarrier of FIG. 18 engaging a track section;

FIG. 27 shows an illustrative diagrammatic plan view of a storage,retrieval and processing system of a further embodiment of the presentinvention that includes destination containers of FIG. 9;

FIG. 28 shows a illustrative diagrammatic view of a storage, retrievaland processing system of a further embodiment of the present inventionthat includes multiple sets of multiple layers of arrays of bins;

FIG. 29 shows an illustrative diagrammatic view of a storage, retrievaland processing system of a further embodiment of the present inventionthat includes a tower of multiple arrays of bins;

FIG. 30 shows an illustrative diagrammatic view of a storage, retrievaland processing system of a further embodiment of the present inventionthat includes a line of towers of multiple arrays of bins; and

FIG. 31 shows an illustrative diagrammatic view of a storage, retrievaland processing system of a further embodiment of the present inventionthat includes an array of towers of multiple arrays of bins.

The drawings are shown for illustrative purposes only.

DETAILED DESCRIPTION

In accordance with an embodiment, the invention provides a storage,retrieval and processing system that includes a plurality of bins, whereeach bin includes objects to be distributed by the system. The pluralityof bins are provided in at least a partially generally circulararrangement. The programmable motion device includes an end effector forgrasping and moving any of the objects, and the programmable motiondevice is capable of reaching any of the objects within the plurality ofbins. The storage and retrieval system also provides a plurality ofdestination containers for receiving any of the objects from theplurality of bins, and the plurality of destination containers areprovided in a region that is generally within the at least partiallygenerally circular arrangement of the plurality of bins.

In accordance with certain embodiments, the invention automates thepicking and the storage and retrieval operations. The system provides anautomated storage and retrieval system that instead of picking andmoving entire totes out of storage, is able to pick only the requirednumber of individual items out of storage. In some embodiments, thesystem works by having a robot coupled to a movable platform that isable to go to storage bins and drawers, and to use a programmable motiondevice (e.g., a robot) to recognize and separate individual items inthose drawers so that it may automatically pick desired individual itemsout of the bins or drawers.

In certain embodiments, the system further works by optionally havingthe robot carry with it a number of destination bins, so that thoseitems need not be re-sorted later. Instead they are carried in a numberof separate bins so that they may remain separated and not mixed up withother retrieved items.

Further, the system has, in certain embodiments, a range of applicationsincluding the ability to replenish retail stores with stock as is donein many distribution centers (DCs) today. In this break-pack process,items sold at stores are replenished by distribution centers, andsystems of the invention in a DC enables the picking of those itemsneeded to be picked from stores so as to replenish stores. The systemtherefore reduces the amount of labor required to do this compared withother systems.

With reference to FIG. 1, the system includes a set 10 of a plurality ofbins 12 that are provided in at least a partially generally circulararrangement. Each of the bins 12 may be open or may be provided as adrawer within a cabinet 8. With reference to FIG. 2, when the bins 12are provided as drawers, the drawers may be automatically actuatable bya drive mechanism 6 (such as a bidirectional solenoid actuator) to movethe drawer out of and into the cabinet 8. Each of the bins 12 faces intothe center of the generally semicircular arrangement. In accordance withcertain embodiments, the bins may be originally filled with objects tobe processed, which may for example, be homogenous sets of objects to beretrieved and delivered to destinations to fulfill orders. The bins 12may be provided by manufacturers, or may be filled by human personnel.In further embodiments, the bins may be filled by other programmablemotion devices, and may be provided to the set 10 via automaticallycontrolled carriers as discussed further below.

With reference to FIG. 3, the set 10 (or layer) of a plurality of bins,may include an opening 14 through which automated carriers 16 may beprovided that each carry a destination bin 18. An articulated arm 20 isalso provided that is suspended from a support structure 22. Theunderside of the support structure also includes a perception system 50.The articulated arm 20 includes an end effector that is able to reachinto each of the plurality of bins 12, grasp objects within each of thebins, and move objects to any of the destination containers 18. Asnoted, the bins 12 may be provided as drawers, in which case either thearticulated arm may be programmed with the functionality to open thedrawers, or in certain embodiments, the drawers may be automated asdiscussed above such that the one or more drawers that need to be opened(as they need to be opened), may be automatically opened and then closedafter an object is grasped from the bin. Also noted above, the bins 12may originally be filled by providing the full bins 12 to the system viaautomated carriers, and the articulated arm may be employed to lift thefull bins 12 into the sets 10. The automated carriers may also beprovided with position detection means, or may be provided on a tracksystem that includes sensors that scan markings on the carriers to knowwhere each carrier is at all times as discussed further below.

The perception system 50 is mounted above the bins of objects to beprocessed next to the base of the articulated arm 20, looking down. Inthe event that the perception system 50 is unable to sufficiently seeinto the bins 12 when open, the system may employ additional perceptionsystems 52 mounted to the support structure 22, at least one of whichmay provide a better view of any objects in a bin 12. The perceptionsystem 50, for example and as shown in FIG. 4, may include (on theunderside thereof), a camera 72, a depth sensor 74 and lights 76. Acombination of 2D and 3D (depth) data is acquired. The depth sensor 74may provide depth information that may be used together with the cameraimage data to determine depth information regarding the various objectsin view. The lights 76 may be used to remove shadows and to facilitatethe identification of edges of objects, and may be all on during use, ormay be illuminated in accordance with a desired sequence to assist inobject identification. The system uses this imagery and a variety ofalgorithms to generate a set of candidate grasp locations for theobjects in the bin as discussed in more detail below.

FIG. 5 shows an image view from the perception unit 50. The image viewshows a bin 44 in an input area 46, and the bin 44 contains objects 78,80, 82, 84 and 86. In the present embodiment, the objects arehomogenous, and are intended for distribution to different break-packpackages. Superimposed on the objects 78, 80, 82, 84, 86 (forillustrative purposes) are anticipated grasp locations 79, 81, 83 and 85of the objects. Note that while candidate grasp locations 79, 83 and 85appear to be good grasp locations, grasp location 81 does not becauseits associated object is at least partially underneath another object.The system may also not even try to yet identify a grasp location forthe object 84 because the object 84 is too obscured by other objects.Candidate grasp locations may be indicated using a 3D model of the robotend effector placed in the location where the actual end effector wouldgo to use as a grasp location as shown in FIG. 5. Grasp locations may beconsidered good, for example, if they are close to the center of mass ofthe object to provide greater stability during grasp and transport,and/or if they avoid places on an object such as caps, seams etc. wherea good vacuum seal might not be available.

If an object cannot be fully perceived by the detection system, theperception system considers the object to be two different objects, andmay propose more than one candidate grasps of such two differentobjects. If the system executes a grasp at either of these bad grasplocations, it will either fail to acquire the object due to a bad grasppoint where a vacuum seal will not occur (e.g., on the right), or willacquire the object at a grasp location that is very far from the centerof mass of the object (e.g., on the left) and thereby induce a greatdeal of instability during any attempted transport. Each of theseresults is undesirable.

If a bad grasp location is experienced, the system may remember thatlocation for the associated object. By identifying good and bad grasplocations, a correlation is established between features in the 2D/3Dimages and the idea of good or bad grasp locations. Using this data andthese correlations as input to machine learning algorithms, the systemmay eventually learn, for each image presented to it, where to bestgrasp an object, and where to avoid grasping an object.

As shown in FIGS. 6A and 6B, the perception system may also identifyportions of an object that are the most flat in the generation of goodgrasp location information. In particular, if an object includes atubular end and a flat end such as object 87, the system would identifythe more flat end as shown at 88 in FIG. 6B. Additionally, the systemmay select the area of an object where a UPC code appears, as such codesare often printed on a relatively flat portion of the object tofacilitate scanning of the barcode.

FIGS. 7A and 7B show that for each object 90, 92, the grasp selectionsystem may determine a direction that is normal to the selected flatportion of the object 90, 92. As shown in FIGS. 8A and 8B, the roboticsystem will then direct the end effector 94 to approach each object 90,92 from the direction that is normal to the surface in order to betterfacilitate the generation of a good grasp on each object. By approachingeach object from a direction that is substantially normal to a surfaceof the object, the robotic system significantly improves the likelihoodof obtaining a good grasp of the object, particularly when a vacuum endeffector is employed.

The invention provides therefore in certain embodiments that graspoptimization may be based on determination of surface normal, i.e.,moving the end effector to be normal to the perceived surface of theobject (as opposed to vertical or gantry picks), and that such grasppoints may be chosen using fiducial features as grasp points, such aspicking on a barcode, given that barcodes are almost always applied to aflat spot on the object.

With reference to FIGS. 9, and 10, each of the automated carriers mayinclude set of controllable omnidirectional wheels 100, such as theMecanum wheels sold by Mecanum AB of Sweden. Each wheels 100 isgenerally a conventional wheel with a series of controllable rollers 102attached to the circumference of each wheel. While the wheels 100provide movement in directions as shown at A and B in FIG. 10, actuationof the rollers 102 (e.g., with limited controlled actuation of thewheels 100) provide movement in directions as shown at C and D in FIG.10.

With reference to FIGS. 11 and 12, in accordance with furtherembodiments, the system may include multiple layers of sets 10 of bin 12stacked upon one another. The systems employ a support structure 22 thatsupports an articulated arm 20, as well as a platform 24 on whichcarriers 16 and containers 18 are provided. The systems also include alift/lowering mechanism 96 that lifts or lowers the structure 22 bymeans of a pulley 98 such that all layers of sets of bins may beaccessed. The movable platform 24 provides a floor that moves with theplatform 24, and the destination containers 18 may be provided on themovable floor so that they may be accessed as the articulated arm 20 ismoved up and down with to access the different layers 10 of sets ofbins. One or more ramps 26 may also be provided that facilitate theautomated carriers 16 accessing the interior of the system.

In certain embodiments that provide the bins 12 as actuatable drawers,as the platform is raised to a level, the system (knowing which drawerswill need to be accessed at that level) will cause the selected drawersto automatically open when the platform reaches each respective layer.The system will also know which destination bin is carried by eachcarrier, and will know where each carrier is located at all times. Acentral processor (e.g., located within the support structure 22 or at aphysically separate location) 60, may communicate with the articulatedarm 20 including the end effector, will communicate with each actuator6, and communicate with each of the automated carriers 16. As shown inFIG. 2, certain (e.g., some or all) of the layers of bins may be fullycircular as shown at 11.

In accordance with a further embodiment, the invention provides afurther processing system for processing objects that includes aplurality levels of a plurality of bins including objects to bedistributed by the processing system, the plurality of bins beingprovided in at least a partially generally circular arrangement. Theprocessing system also includes a programmable motion device thatincludes an end effector for grasping and moving any of the objects, andthe programmable motion device is capable of reaching any of the objectswithin the plurality of levels of the plurality of bins. The processingsystem further includes at least one destination container for receivingany of the objects from the plurality of levels of the plurality ofbins, the at least one destination containers being provided in a regionthat is generally within the at least partially generally circulararrangement of the plurality of bins of a level of the plurality ofbins.

FIG. 13 shows (in a plan view) a system in accordance with a furtherembodiment of the present invention that includes a plurality of stacks108 of sets 110 of bins 112 similar to sets 10 of bins 12 of FIGS. 1, 2,11 and 12. Between the stacks 108 of sets of bins, run tracks 120 onwhich actuatable carriers 126 may run, as well as a plurality ofscanners 122 for scanning identifying indicia on the bottoms of thecarriers 126 to maintain/confirm knowledge of where each carrier islocated on the tracks. Conversely, the tracks may include indicia at122, and sensors on the carrier may detect the indicia as they move overthe indicia on the track. The tracks 120 may also include on/off runs124 to facilitate the carriers accessing the stacks 108.

In accordance with an embodiment, for example, the tracks may beprovided by paint with a particular reflective characteristic, andsensors on the bottom of the carrier 126 may be programmed to follow thepainted track. Further sensors may cause the carrier to change directionwhen, for example, a sensor or indicia 122 is encountered. The carriersmay still be able to run without a track, for example, to and from thestacks 108 without tracks, but the use of the tracks may reducecomputation expenses.

For example, FIG. 14 shows such a carrier 126 that includes fourillumination sources 32, 34, 36, 38 for illuminating the track beloweach source. FIG. 15 shows a top view of the carrier 126, showing theposition of each of the illumination sources 32, 34, 36, 38. FIG. 16shows an underside of the carrier 126, which shows four pairs ofillumination sensors 62, 64, 66, 68. As the carrier 126 moves over atrack section (e.g., a section of track that is under sensor pairs 62,66), the system monitors the amount of light being received at each pairof underside sensors (e.g., each of pair 62 and each of pair 66) todetermine if the amount of illumination being received by each of thepair is generally the same. If much more illumination is received by oneof a pair, the system may assume that the carrier has run off course.Having two such pairs (e.g., 62, 66) for a painted track line, providesfurther robustness to the system. Additionally, sensors (or indicia)132, 134, 136, 138 may be provided on the underside of each carrier 126for communicating with any of indicia (or sensors) 122 on the track.This may assist in providing further security in confirming the locationof a carrier, and/or in providing turning instructions to a carrier.

FIG. 17 shows (again in a plan view) a system 150 in accordance with afurther embodiment of the present invention that includes adiscontinuous track system 152 that runs among one or more stacks 154 ofsets 156 of bins 158 similar to those discussed above. The discontinuoustrack system 152 includes a plurality of track sections 212 that may begenerally in the shape of squares, and carriers 230 may run along thetrack sections 212 in each of two mutually orthogonal directions asdiscussed in more detail below. The track sections may either run intothe stacks 154, may run onto a platform of such stacks, or may stopoutside of the stack, requiring the carrier 230 to travel without theaid of a track within the stack. The track sections 212 may also includeeither sensors or indicia 160 inside each track section that maycommunicate with either indicia or sensors 276 on the underside of eachcarrier 230 as discussed in more detail below and shown in FIGS. 22A,22B and 24A, 24B.

FIG. 18 shows a carrier 230 together with a destination container 18.The carrier 230 may be moved about the track sections 212 (from FIG. 17)bi-directionally in either of two mutually orthogonal directions. Thisis achieved by having the four drive wheel assemblies optionally pivotninety degrees. A plurality of these carriers 230 may be employed on thediscontinuous track system 150 at the same time, engaging a plurality ofstacks 154.

In accordance with certain embodiments therefore, the invention providesa plurality of mobile carriers that may include swivel mounted wheelsthat rotate ninety degrees to cause each mobile carrier to move forwardand backward, or to move side to side. When placed on a grid, suchmobile carriers may be actuated to move to all points on the grid. FIGS.19A and 19B, for example, show a mobile carrier 230 that includes wheels232, 234, 236 and 238 (shown in FIGS. 23A and 23B). Each of the wheelsis mounted on a motor 233, 235, 237, 239 (as best shown in FIG. 23B),and the wheel and motor units are pivotally mounted to the carrier 230as discussed in more detail below. The wheel assemblies (each includinga wheel, its motor and track guides 240) are shown in one position inFIG. 19A, and are shown in a second pivoted position in FIG. 19B. FIG.20A shows an end view of the carrier 30 taken along lines 20A-20A ofFIG. 19A, and FIG. 20B shows an end view of the carrier 30 taken alonglines 20B-20B of FIG. 19B. Similarly, FIG. 21A shows a side view of thecarrier 30 taken along lines 21A-21A of FIG. 19A, and FIG. 21B shows aside view of the carrier 30 taken along lines 21B-21B of FIG. 19B.

Each carrier 230 also includes a pair of opposing rails 242, 244 forretaining a bin, as well as a raised center portion 246 and stands 243,245 on which a bin may rest. A pair of independently actuated paddles248, 250 are also provided. Each paddle 248, 250 may be rotated upward(as shown at B in FIG. 20A) to retain a bin on the carrier, or mayrotated downward to permit a bin to be moved onto or off of a carrier.The paddles 248, 250 are shown rotated downward in FIGS. 19A-21B.

Note that the orientation of the carrier 230 (also a bin on the carrier)does not change when the carrier changes direction. Again, a bin may beprovided on the top side of the carrier, and may be contained by binrails 242, 244 on the sides, as well actuatable paddles 248, 250. Aswill be discussed in further detail below, each paddle 248,250 may berotated 180 degrees to either urge a bin onto or off of a shelf, or (ifboth are actuated) to retain a bin on the carrier during transport. Eachpaddle may therefore be used in concert with movement of the carrier tocontrol movement of the bin with respect to the carrier 230. Forexample, when on paddle is flipped into an upward position, it may beused to urge the bin onto a shelf or rack while the carrier is movingtoward the shelf or rack. Each carrier may also include one or moreemergency stop switches 252 for a person to use to stop the movement ofa carrier in an emergency, as well as handles 254 to enable a person tolift the carrier if needed.

FIG. 22A shows a bottom view of the carrier 230 with the wheels in theposition as shown in FIG. 19A, and FIG. 22B shows a bottom view of thecarrier 230 with the wheels in the position as shown in FIG. 19B. FIGS.22A and 22B show all of the wheels 232, 234, 236 and 238, and each ofthe motors 233, 235, 237 and 238 is also shown in FIG. 22B. As may beseen in FIGS. 22A and 22B, the entire wheel assemblies including thewheel, guide rollers and the wheel motor, each pivot as a unit. Withreference to FIGS. 23A and 23B, each pair of wheel assemblies may, in anembodiment, be pivoted by a common pivot motor 256 that is coupled tothe wheel assemblies via linkages 258. FIG. 23A shows a pair of wheelassemblies in a position as shown in FIG. 23A, and FIG. 23B shows thepair of wheel assemblies in a position as shown in FIG. 19B. The wheelassemblies are designed to be able to pivot the wheels around corners ofa track section when the carrier is directly above a track section.FIGS. 24A and 24B show views similar to the underside views of FIGS. 22Aand 22B but with a track section 212 superimposed on the Figures to showthe relation of the wheel positions to the track section. Note that thewheels pivot around each of the corners of the track section. When thecarrier is centered over the track section, therefore, the wheels may bepivoted such that the carrier may move in a direction that is orthogonalto a prior direction without requiring that the carrier itself beturned. The orientation of the carrier is therefore maintained constantwhile the carrier is moved about an array of tracks sections.

The movement of the carrier 230 about an array of track sections isfurther discussed below with regard to FIGS. 25A-25C. In short as acarrier leaves one track section, it travels toward an adjacent tracksection, and if at all misaligned, will realign itself. The realignmentof the guide rollers and the tracks may function as follows. While thetwo sets of wheels (232, 234 and 236, 238) may be designed to move thecarrier 230 in a linear direction only, some variations may occur. Thetracks 212 are positioned, though intermittently, close enough to eachother than when a carrier leaves one track and moves toward another 212(as shown at B), its potential variation off course will be small enoughthat the rounded corners of the next adjacent track will urge thecarrier back on course. For example, FIG. 25A shows a carrier 230leaving a track and beginning to approach a next track 212 as thecarrier moves in a direction as indicated at B. As shown in FIG. 25B, ifthe alignment of the carrier 230 is off (possibly from variations in thewheels or the mounting of the wheels, the placement of the tracksections or any other variable), one of the rounded corners 260 of nextadjacent track 212 will become engaged by an on-coming guide wheel 240,and the rounded corner 260 will cause the carrier 230 to move slightlyin a direction (as shown at C) perpendicular to the direction B tocorrect the direction of movement of the carrier 230. If themisalignment is too far off, the carrier may reverse direction and tryto become again aligned, or may stop moving and be recovered. If acarrier does stop moving, the directions of movement of the othercarriers are programmed to avoid the area of the stopped carrier untilit is removed. If an area results in a number of stopped carriers overtime, the alignment of the track(s) in the area may be examined and/orreplaced.

FIG. 25C shows the carrier 230 moving in a direction F as properlyrealigned by the track 212. FIG. 26 shows a close up view of the wheel234 moving in a direction as shown at H to cause the carrier to move inthe direction F, and further shows that the guide rollers 240 rollagainst the track 212 in directions as shown at I. The guide rollers 240do not touch the ground (as does the wheel 234), but simply guide thedirection of the carrier 230 by being urged against the track 212. Infurther embodiments, biasing means such as springs, elastics orpneumatics may be used to urge the guide rollers against the track, andin further embodiments, the tracks may be more triangular shaped at theedges to further facilitate reception of the carriers. If too muchcorrection is required, however, the system may be operatinginefficiently.

Systems of the invention therefore provide for binary steering of theautomated carrier, allowing only bidirectional column and row travel ina grid. One pivot motor may be used for each pair of wheels, with alinkage to pivot the wheel modules. On other embodiments, one pivotmotor and linkage could be used for all four wheels, or each wheel mayhave an independent pivot actuator. The system allows the wheels tofollow square track sections by pivoting around rounded corners of thesquare track sections. The system does not require differential driveline/trajectory following, and keeps the orientation of the carrierfixed throughout all operations.

As shown in FIG. 27 (also in plan view), each set 160 of a stack,instead of containing bins as discussed above, may contain actuatablecarriers 366 for both the storage and the distribution. Some of thecarriers 366 would still move distribution bins 18 as discussed above,while other carriers 366 would contain the storages 162 of the objectssimilar to the bins or drawers 12 of FIGS. 11-3 and 11-13. Thecontrollable carriers 366 may include omnidirectional wheels with orwithout track following technology, or pivotal wheel assemblies androllers for following discontinuous tracks as discussed above. With thissystem, the maintenance of the storage of the objects within each towermay also be effected through the use of the actuatable carriers. Infact, the replenishment of the objects in the storages 162 may beaccomplished at the same time as the retrieval of objects from the sameset 160, providing a highly dynamic and fluid system.

Generally, adding more levels (and more bins) increases the object (SKU)capacity, and adding more towers (and articulated arms) increases thethroughput. With reference to FIG. 28, the system (two systems areshown), may include instead of a plurality of bins within each tower, asingle automated carrier 28 that moves as a unit among different towers,and the single automated carrier 28 may be raised and lowered on a floorof the movable platform 24 as the system access objects within bins onvarious layers. The single automated carrier 28 may includemultidirectional wheels as discussed above with respect to wheels 100that include rollers 102, or the carrier 24 may operate as skid-steerand turn by actuating opposing wheels in opposite directions. Inaccordance with further embodiments, one or more conveyors may be usedto move bins (and carriers) between the towers, wherein the carriers forexample, may drive on and off the conveyors.

As further shown with reference to FIGS. 29-31, any number of such towersystems 308-320 may be provided within a workspace, processing bins ofobjects into destination bins 18 that may be provided in movablecarriers 336 as discussed above with respect to previously discussedcarriers, e.g., either with or without the tracks discussed above. Themovable carriers 336, as well as the articulated arms 20 and automateddrawers, are all in communication with a central computer system 60, orwithin the support structure 22, that directs the movement of all ofthese parts. Again, the controllable carriers 366 may, for example,include omnidirectional wheels with or without track followingtechnology, or pivotal wheel assemblies and rollers for followingdiscontinuous tracks as discussed above. In further embodiments, each ofthe towers may communicate with other towers, as well as an overallcontrol system 60 that knows which bins of objects to be sorted areprovided in each of the towers. For rarely selected objects, forexample, the system may use one bin of one tower, and direct anydestination bins to that tower that require the rarely selected object.In further embodiments, the control system 60 may control all of thedevices and movable carriers, and all may communicate with one anothervia wireless communication.

Those skilled in the art will appreciate that numerous modifications andvariations may be made to the above disclosed embodiments with departingfrom the spirit and scope of the present invention.

What is claimed is:
 1. A storage, retrieval and processing system forprocessing objects, said storage, retrieval and processing systemcomprising: a plurality of bins including objects to be distributed bythe processing system, said plurality of bins being provided in at leasta partially generally circular arrangement; a programmable motion devicethat includes an end effector for grasping and moving any of theobjects, said programmable motion device being capable of reaching anyof the objects within the plurality of bins; and a plurality ofdestination containers for receiving any of the objects from theplurality of bins, said plurality of destination containers beingprovided in a region that is generally within the at least partiallygenerally circular arrangement of the plurality of bins.
 2. The storage,retrieval and processing system as claimed in claim 1, wherein theplurality of bins is provided as a plurality of drawers.
 3. The storage,retrieval and processing system as claimed in claim 1, wherein each ofthe plurality of destination containers is provided on an automatedcarrier that is able to move the respective destination container. 4.The storage, retrieval and processing system as claimed in claim 1,wherein the processing system includes a plurality of stacks of aplurality of bins that are provided in at least a partially generallycircular arrangement, and wherein the programmable motion device ismovable among the plurality of stacks of the plurality of bins.
 5. Thestorage, retrieval and processing system as claimed in claim 4, whereinthe destination containers are positioned on a movable floor that ismovable among the plurality of levels of the plurality of bins.
 6. Thestorage, retrieval and processing system as claimed in claim 5, whereinthe movable floor is coupled to a support structure to which theprogrammable motion device is attached.
 7. The storage, retrieval andprocessing system as claimed in claim 1, wherein the storage andretrieval system includes a plurality of tracks on which the pluralityof destination containers may be moved.
 8. The storage, retrieval andprocessing system as claimed in claim 7, wherein the tracks are formedof discontinuous track sections.
 9. The storage, retrieval andprocessing system as claimed in claim 1, wherein the destinationcontainers are movable on automated carriers that are able to move intwo mutually orthogonal directions.
 10. The storage, retrieval andprocessing system as claimed in claim 1, wherein each of the pluralityof bins is provided on an automated carrier that is able to move thebin.
 11. A storage, retrieval and processing system for processingobjects, said storage, retrieval and processing system comprising: aplurality vertically stacked levels of a plurality of bins includingobjects to be distributed by the processing system, said plurality ofbins being provided in at least a partially generally circulararrangement; a programmable motion device that includes an end effectorfor grasping and moving any of the objects, said programmable motiondevice being capable of reaching any of the objects within the pluralityof levels of the plurality of bins; and at least one destinationcontainer for receiving any of the objects from the plurality of levelsof the plurality of bins, said at least one destination containers beingprovided in a region that is generally within the at least partiallygenerally circular arrangement of the plurality of bins and is movablewith the programmable motion device.
 12. The storage, retrieval andprocessing system as claimed in claim 11, wherein the plurality of binsare provided as a plurality of drawers.
 13. The storage, retrieval andprocessing system as claimed in claim 11, wherein at least onedestination container is provided on an automated carrier that is ableto move the respective destination container.
 14. The storage, retrievaland processing system as claimed in claim 11, wherein the programmablemotion device is movable to and from the plurality of vertically stackedlevels.
 15. The storage, retrieval and processing system as claimed inclaim 11, wherein the at least one destination container is positionedon a movable floor that is movable among the plurality of verticallystacked levels of the plurality of bins.
 16. The storage, retrieval andprocessing system as claimed in claim 15, wherein the movable floor iscoupled to a support structure to which the programmable motion deviceis attached.
 17. The storage, retrieval and processing system as claimedin claim 16, wherein the programmable motion device is suspended fromthe support structure.
 18. The storage, retrieval and processing systemas claimed in claim 11, wherein the storage and retrieval systemincludes a plurality of tracks on which the at least one destinationcontainer may be moved.
 19. The storage, retrieval and processing systemas claimed in claim 18, wherein the tracks are formed of discontinuoustrack sections.
 20. The storage, retrieval and processing system asclaimed in claim 19, wherein the discontinuous track sections areprovided as an array of discontinuous track sections.
 21. The storage,retrieval and processing system as claimed in claim 11, wherein thedestination containers are movable on automated carriers that are ableto move in two mutually orthogonal directions.
 22. A method of storing,retrieving and processing objects, said method comprising the steps of:providing a plurality of bins including objects to be processed, saidplurality of bins being provided in at least a partially circulararrangement; receiving at least one destination container within an areaat least partially enclosed by the at least partially circulararrangement of the plurality of bins; moving the end effector of theprogrammable motion device toward the at least one bin of the pluralityof bins; grasping an object from the at least one bin using the endeffector; moving the object with the end effector toward the at leastone destination container; and placing the object in the at least onedestination container with the end effector.
 23. The method as claimedin claim 22, wherein the plurality of bins is provided as a plurality ofdrawers.
 24. The method as claimed in claim 22, wherein the methodfurther includes the step of moving the programmable motion device amonga plurality of vertically stacked levels of the plurality of bins thatare each provided in at least a partially generally circulararrangement.
 25. The method as claimed in claim 24, wherein the methodfurther includes the step of moving the at least one destinationcontainer with the programmable motion device among the plurality ofvertically stacked levels of the plurality of bins.
 26. The method asclaimed in claim 25, wherein the at least one destination container isprovided with a plurality of destination containers that are positionedon a movable floor that is movable among the plurality of verticallystacked levels of the plurality of bins.
 27. The method as claimed inclaim 26, wherein the movable floor is coupled to a support structure towhich the programmable motion device is attached.
 28. The method asclaimed in claim 22, wherein the storage and retrieval system includes aplurality of tracks on which the at least one destination container maybe moved.
 29. The method as claimed in claim 28, wherein the pluralityof tracks are provided as an array of discontinuous track sections. 30.The method as claimed in claim 29, wherein the method further includesthe step of changing a direction of movement of a movable carrier from afirst direction to a second direction that is generally orthogonal tothe first direction.
 31. The method as claimed in claim 29, wherein themethod further includes the step of moving the at least one destinationcontainer on a movable carrier that is adapted to move along thediscontinuous track sections.